Autonomous floor cleaner with brushroll positioning

ABSTRACT

An autonomous floor cleaner includes a tank adapted to hold liquid and/or debris, a brushroll to agitate a surface to be cleaned, and a position setting mechanism for the brushroll. The position setting mechanism can include a height setting feature on the tank to set the height of the brushroll within a brush chamber.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application claims the benefit of U.S. Provisional Application No. 63/330,528 filed Apr. 13, 2022, which is incorporated herein by reference in its entirety.

BACKGROUND

Autonomous floor cleaners can move without the assistance of a user or operator to clean a floor surface. One category of floor cleaner or “robot” has a vacuuming system and is configured to vacuum debris into a collection tank carried on the robot. Another category of robot includes a recovery system that extracts liquid and debris from the floor surface, and often also has a fluid delivery system that delivers cleaning fluid to the floor surface. The robot can move randomly while cleaning the floor surface or use a mapping/navigation system for guided navigation about the surface.

One noted problem with current autonomous floor cleaners is that many are specifically configured for cleaning of hard floor surfaces or for soft floor surfaces, but do not perform well on both hard and soft floor surfaces.

BRIEF SUMMARY

In one aspect of the disclosure, an autonomous floor cleaner includes an autonomously moveable housing comprising a brush chamber, an autonomous drive system, a tank adapted to hold at least one of liquid and debris, a brushroll mounted within the brush chamber, a brushroll drive system comprising a brushroll motor operably coupled with the brushroll, and a brushroll height setting feature coupled with the tank and configured to engage the brushroll to set the height of the brushroll within the brush chamber.

In another aspect of the disclosure, an autonomous floor cleaner includes an autonomously moveable housing comprising a brush chamber, an autonomous drive system, a tank adapted to hold at least one of liquid and debris, dual-rotating brushrolls mounted within the brush chamber, the dual-rotating brushrolls comprising a first brushroll and a second brushroll, a brushroll drive system comprising a brushroll motor operably coupled with the dual-rotating brushrolls, and a brushroll height setting mechanism configured to set the first brushroll at a first height setting in a first cleaning mode and to set the first brushroll at a second, different height setting in a second cleaning mode.

According to these and other aspects of the disclosure, the tank may comprise a dry tank adapted to hold dry debris, a wet tank adapted to hold liquid and debris, or a tank adapted to hold wet or dry debris.

According to these and other aspects of the disclosure, the brushroll may comprise a bristle brushroll, a microfiber brushroll, or a hybrid brushroll that includes multiple agitation materials to optimize cleaning performance for different cleaning modes, including dry and wet cleaning.

According to these and other aspects of the disclosure, the robot may include multiple, interchangeable brushrolls.

According to these and other aspects of the disclosure, the robot may include multiple, interchangeable tanks.

According to these and other aspects of the disclosure, the robot is a multi-surface robot that can be used to clean hard floor surfaces such as tile and hardwood and soft floor surfaces such as carpet, by performing both dry and wet cleaning.

These and other features and advantages of the present disclosure will become apparent from the following description of particular embodiments, when viewed in accordance with the accompanying drawings and appended claims.

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.

DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a schematic view of a surface cleaning apparatus in the form of an autonomous floor cleaner or robot according to one aspect of the disclosure;

FIG. 2 is a schematic view showing a dry tank and first brushroll installed on the robot of FIG. 1 , with the dry tank having a brushroll height setting feature configured to engage the brushroll;

FIG. 3 is a schematic view showing a wet tank and second brushroll installed on the robot of FIG. 1 , with the wet tank having a brushroll height setting feature configured to engage the brushroll;

FIG. 4 is a schematic view of a brushroll position setting mechanism for the robot, and showing the dry tank and first brushroll installed on the robot;

FIG. 5 is a schematic view of a brushroll position setting mechanism for the robot, and showing the wet tank and second brushroll installed on the robot;

FIG. 6 is a schematic view of an autonomous floor cleaner or robot according to another aspect of the disclosure, the robot having a dual brushroll configuration and showing a dry tank installed on the robot; and

FIG. 7 is a schematic view of the robot of FIG. 6 , showing a wet tank installed on the robot.

DETAILED DESCRIPTION

The invention generally relates to an autonomous floor cleaner. Aspects of the disclosure relate to an autonomous floor cleaner with height-setting features for a brushroll.

The term “debris” includes dirt, dust, soil, hair, stains, and other debris, unless otherwise noted. The term “cleaning fluid” includes liquids such as water or a cleaning solution, steam or vapor, unless otherwise noted.

FIG. 1 is a schematic view of an autonomous floor cleaner, or robot 10, according to one aspect of the present disclosure. As discussed in further detail below, the robot 10 is provided with various features and improvements, which are described in further detail below. As illustrated herein, the robot 10 mounts and/or carries the components of various functional systems of a deep cleaner in an autonomously moveable unit or housing 12, including a tank 14 and a brushroll 16. The tank 14 is removably mounted to the housing 12 and adapted to hold debris, liquid, or a combination of debris and liquid, and the brushroll 16 mounted in a brush chamber 18. As described in further detail below, the tank 14 has features that interact with the brushroll 16 to control the position of the brushroll 16 within the brush chamber 18. In this way, the brushroll 16 can be set to a desired amount of floor contact.

In one aspect, the tank 14 has a brushroll height setting feature 70 configured to engage the brushroll 16 to set the position or height of the brushroll 16 within the brush chamber 18. The brushroll height setting feature 70 may comprise a fixed or preset engagement feature, such that the brushroll height setting feature 70 is configured to set the brushroll 16 to a predetermined height within the brush chamber 18. In another embodiment, the brushroll height setting feature 70 is adjustable, so that the tank 14 can set the brushroll 16 to various heights. The former may be preferred, for example, for a robot having multiple interchangeable tanks, where each tank sets a brushroll to a predetermined height. The latter may be preferred, for example, for a robot having one tank that can engage multiple interchangeable brushrolls, so that the height of each brushroll can be set individually by one tank.

Utilizing the height-setting features disclosed herein, the robot 10 can use multiple types of brushrolls, such as brushrolls having different diameters, with different amounts of designed floor contact, and can easily accommodate different brushrolls with the same mounting and drive system.

The robot 10 can include at least one cleaning system, such as a vacuum collection system, a fluid delivery system, a fluid recovery system, a sweeping system, or a mopping system. In one configuration, the robot 10 is adapted for both dry and wet cleaning, and includes interchangeable tanks, including a first or dry tank 14 (FIGS. 1-2 ) and a second or wet tank 40 (FIG. 3 ). Each tank 14, 40 can be installed on and removed from the housing 12. The housing 12 can include a tank receiver 42 in which the tanks 14, 40 can be installed, one at a time, and the tanks 14, 40 can be installed through a top of side of the housing 12. A tank latch (not shown) can secure the tank 14, 40 within the tank receiver 42. Still other tanks can be provided, and can be interchangeable with at least one other tank. In yet other embodiments of the robot 10, only one tank is provided.

Optionally, the robot 10 includes interchangeable brushrolls, including a first or bristle brushroll 16 (FIGS. 1-2 ) and a second or microfiber brushroll 60 (FIG. 3 Each brushroll 16, 60 can be installed on and removed from the brush chamber 18.

The brushrolls 16, 60 may differ from each other in at least one aspect, such as by having different agitation elements, different diameters, or different amounts of designed floor contact, or any combination thereof. Some non-limiting examples of agitation elements include bristles, microfiber material, paddles, flappers, flails, wires, elongated teeth or short nubs, or a scrubbing material, such as a non-woven or open cell foam scrubbing material. Still other brushrolls can be provided, and can be interchangeable with at least one other brushroll.

The robot 10 can include at least one user interface 20 through which a user can interact with the robot 10. The interface 20 can enable operation and control of the robot 10 by the user, and can also provide feedback information from the robot 10 to the user. The user interface 20 can be electrically coupled with electrical components, including, but not limited to, circuitry electrically connected to various components of the fluid delivery and collection systems of the robot 10. The user interface 20 can have one or more input controls, such as but not limited to buttons, triggers, toggles, keys, switches, touch screens, or the like, operably connected to systems in the robot 10 to affect and control its operation. In one example, a power button controls the supply of power to one or more electrical components of the robot 10. The user interface 20 communicate visually and/or audibly. Additionally or alternatively, a user interface for the robot 10 can be provided as an application executed on a smartphone, tablet computer or the like for controlling one or more functions of the robot 10.

The robot 10 can further include a controller 22 operably coupled with the various function systems of the robot 10 for controlling its operation. The controller 22 can be a microcontroller unit (MCU) that contains at least one central processing unit (CPU). The controller 22 can be operably coupled with the user interface 20 for receiving inputs from a user and for providing one or more indicia about the status of the robot 10 to the user, and can further be operably coupled with at least one sensor 24 for receiving input about the environment and can use the sensor input to control the operation of the robot 10. Some non-limiting examples of sensors 24 include distance sensors for determining the distance of the robot 10 relative to obstacles, cliff sensors that provide distance feedback so that the robot 10 can avoid excessive drops such as stairwells or ledges, bump sensors for determining front or side impacts to the robot 10, wall following sensors that provide distance feedback so that the robot 10 can follow near a wall without contacting the wall, accelerometers to sense linear, rotational and magnetic field acceleration, lift-up sensors which detect when the robot 10 is lifted off the surface to be cleaned, such as when the user picks up the robot 10, and floor condition sensors, such as an infrared debris sensor, a stain sensor, an odor sensor, and/or a wet mess sensor, for detecting a condition of the surface to be cleaned.

The robot 10 can include a power supply on-board the housing 12, which can be a rechargeable battery 26 (e.g. a battery pack or a plurality of battery cells). In one example, the battery 26 can be a lithium ion battery. An appropriate charger can be provided with the robot 10. In one embodiment, the robot 10 can have a charging port used to charge the battery 26. A charging cable (not shown) can be provided for plugging the robot 10 into a household outlet. In an alternative embodiment, the robot 10 can have charging contacts on the housing 12, and a docking station (not shown) can be provided for docking the robot 10 for recharging the battery 26.

The autonomous drive system is configured for autonomously moving the robot 10 over the surface to be cleaned. The robot 10 can be configured to move randomly about a surface while cleaning the floor surface, using input from various sensors to change direction or adjust its course as needed to avoid obstacles, or can include a navigation/mapping system for guiding the movement of the robot 10 over the surface to be cleaned. In one embodiment, the robot 10 includes a navigation and path planning system that is operably coupled with the drive system. The system builds and stores a map of the environment in which the robot 10 is used, and plans paths to methodically clean the available area. In another embodiment, an artificial barrier system (not shown) can be provided with the robot 10 for containing the robot 10 within a user-determined boundary.

The drive system can include drive wheels 28 for driving the robot 10 across a surface to be cleaned. The drive wheels 28 can be operated by a common drive motor or individual drive motors (not shown) coupled with the drive wheels 28 by a transmission, which may include a gear train assembly or another suitable transmission. The drive system can receive inputs from the controller 22 for driving the robot 10 across a floor, based on inputs from the navigation/mapping system. The drive wheels 28 can be driven in a forward or reverse direction in order to move the housing 12 forwardly or rearwardly, and can be operated simultaneously or individually in order to turn the housing 12 in a desired direction. The controller 22 can receive input from the navigation/mapping system for directing the drive system to move the robot 10 over the surface to be cleaned. The navigation/mapping system can include a memory that stores maps for navigation and inputs from various sensors, which is used to guide the movement of the robot 10.

In FIG. 1 , the first tank 14 and brushroll 16 are mounted on the robot 10. The brushroll 16 is mounted for rotation about a substantially horizontal axis X, relative to the surface over which the robot 10 moves. A drive assembly 30 including a brush motor 32 can be provided within the robot 10 to drive the brushroll 16. A drive transmission, for example including a belt 34, operably connects the motor 32 with the brushroll 16 for transmitting rotational motion of the motor 32 to the brushroll 16. Alternatively, the brushroll 16 can be driven mechanically by the autonomous movement of the robot 10.

The brushroll 16 can be mounted at a front of the robot 10, with the tank 14 generally above the brushroll 16 and also at the front of the robot 10. As used herein for the robot 10, “front” or “forward” and variations thereof are defined relative to the direction of forward travel of the autonomous robot 10, unless otherwise specified. In other configurations, the brushroll 16 and tank 14 can be mounted elsewhere on the robot 10, including at or near a middle of the robot 10 or a rear of the robot 10.

For dry cleaning, the robot 10 can have a vacuum collection system. The vacuum collection system can include a working air path 44 through the robot 10 having an air inlet and an air outlet, a suction source 46 in fluid communication with the air inlet for generating a working air stream, and the dry tank 14, which collects debris from the working airstream for later disposal. The suction source 46 can include a vacuum motor 48 carried by the housing 12, fluidly upstream of the air outlet (not shown), and can define a portion of the working air path.

The air inlet of the working air path 44 can be defined by an inlet opening 36 in the housing 12, which can open to the brush chamber 18. The brushroll 16 is rotatably mounted in the inlet opening 36 to contact a surface to be cleaned below the housing 12. A suction nozzle inlet 50 in fluid communication with the inlet opening 36 can be positioned in close proximity to the brushroll 16 to collect liquid and/or debris directly from the brushroll 16. For example, the suction nozzle inlet 50 can include an inlet port at a top and/or rear side the brush chamber 18. In other embodiments, the air inlet of the working air path 44 can be defined by the suction nozzle inlet 50, which can be positioned to confront the surface to be cleaned to remove liquid and debris from the surface, rather than the brushroll 16.

The brush chamber 18 can be partially formed by housing 12 and partially by the tank 14, so that when the tank 14 is removed, a portion of the brush chamber 18 is removed and a portion of the brush chamber 18 is left with the housing 12. In the embodiment shown, the tank 14 can form a top wall 38 of the brush chamber 18 when installed on the housing 12. As such, removal of the tank 14 removes the top wall 38 and exposes the brushroll 16 in the brush chamber 18. When the tank 14 is removed, the brushroll 16 can be removed for cleaning, or exchanged for the other brushroll 60 (FIG. 3 ). In this configuration, the inlet opening 36 may be left behind as well, with the inlet opening 36 generally being formed by front and rear sides of the brush chamber 18. In another embodiment, the entire, or substantially the entire, brush chamber 18 can be removable with the tank 14. Such an embodiment an include the inlet opening 36 and/or the brushroll 16 being removable with the tank 18.

The top wall 38 can be formed by a wall of the tank 14, which may be a lower wall or a bottom wall of the tank 14. Removal of the tank 14 removes the top wall 38 and opens a top of the brush chamber 18. Installation of the tank 14 thereby closes the top of the brush chamber 18. In one embodiment, the brush chamber 18 has a top opening that is sized to accommodate insertion and/or removal of the brushroll 16 through the top opening, and the top wall 38 is sized to close the top opening. The top opening may therefore, in some embodiment, be considered a brushroll insertion opening. The interface between the top wall 38 and top opening of the brush chamber 18 is preferable fluid-tight, such as by the provision of a suitable seal or seals, such that the working air flow cannot escape the brush chamber 18 via the top opening when the tank 14 is installed.

The dry tank 14 can also define a portion of the working air path, and is in fluid communication with the suction nozzle inlet 50. Optionally, a separator (not shown) can be formed in a portion of dry tank 14 for separating fluid and entrained debris from the working airstream. Some non-limiting examples of separators include a cyclone separator, a filter screen, a foam filter, a HEPA filter, a filter bag, or combinations thereof. Optionally, a pre-motor filter and/or a post-motor filter (not shown) can be provided in the working air path 44 as well. The working air path 44 can further include various conduits, ducts, or tubes for fluid communication between the various components of the collection system. The vacuum motor 48 can be positioned fluidly downstream or fluidly upstream of the dry tank 14 in the working air path 44.

For wet cleaning, the robot 10 can have a fluid delivery system. During the wet mode of operation, liquid is applied to the floor surface. The fluid delivery system can include a supply tank 52 for storing a supply of cleaning fluid and at least one fluid distributor 54 in fluid communication with the supply tank 52. The cleaning fluid can be a liquid such as water or a cleaning solution specifically formulated for hard surface cleaning. The fluid distributor 54 can be one or more spray nozzles or spray tips provided on the housing 12 of the robot 10. Alternatively, the fluid distributor 54 can be a manifold having multiple outlets.

The fluid distributor 54 can be positioned to dispense cleaning fluid within the brush chamber 18, such as onto the brushroll 16. Alternatively, the fluid distributor 54 can be configured for spraying directly onto a floor over which the housing 12 autonomously moves, and can in particular dispense cleaning fluid beneath the housing 12 or outwardly from the housing 12. As yet another alternative, multiple fluid distributors can be provided to dispense cleaning fluid onto the brushroll 16 and directly onto a floor.

A fluid delivery pump 56 can be provided in a fluid pathway 58 between the supply tank 52 and the fluid distributor 54 to control the flow of fluid to the fluid distributor 54. Various combinations of optional components can be incorporated into the fluid delivery system as is commonly known in the art, such as a heater for heating the cleaning fluid before it is applied to the surface, or one more fluid control and mixing valves.

During the wet mode of operation, liquid and/or debris is recovered from the floor surface. For recovering liquid and/or debris, the robot 10 can have a fluid recovery system, which includes the wet tank 40 (FIG. 3 ) and can share some components with the vacuum collection system. For example, installing the wet tank 40 in the tank receiver 42 positions the wet tank 40 in the working air path 44, and in fluid communication with the suction nozzle inlet 50 and the suction source 46. In other embodiments, the components of the fluid recovery system can be separate from those of the vacuum collection system.

Referring to FIGS. 2-3 , each brushroll 16, 60 includes a rotatable portion including at least one agitation element and a brush bar or dowel supporting the at least one agitation element, a brushroll axis X about which the rotatable portion is rotatable, and a non-rotatable portion disposed at each end of the brush bar. The non-rotatable portion does not rotate about the brushroll axis X, e.g. is stationary while the rotatable portion rotates. The non-rotatable portion can comprise, among other elements, end caps disposed at opposing ends of the dowel. Such end caps can be configured to mount the ends of the brushroll in the brush chamber 18 and couple the brushroll with the drive assembly 30 (FIG. 1 ).

In one embodiment, the brushroll 16 for dry mode cleaning is a bristle-based brushroll and comprises a dowel 62 defining the rotational axis X and a plurality of bristles 64, with the outer ends of the bristles 64 defining a diameter D1 of the brushroll 16. The brushroll 60 for wet mode cleaning is a microfiber-based brushroll and comprises a dowel 66 defining the rotational axis X and microfiber material 68, with the outer ends of the microfiber material 68 defining a diameter D2 of the brushroll 60.

Referring to FIG. 2 , the first or dry tank 14 has a first brushroll height setting feature 70 configured to engage the first brushroll 16 to set the position or height of the brushroll 16 to a first position or a first height H1 within the brush chamber 18. In one embodiment, the optimal position for dry mode cleaning is one in which the outer tips of the bristles 64 just touch the surface to be cleaned S. The first height H1 can therefore be one in which the outer tips of the bristles 64 just touch the surface to be cleaned S.

Referring to FIG. 3 , the second or wet tank 40 has a second brushroll height setting feature 80 configured to engage the second brushroll 60 to set the position height of the brushroll 60 to a second position or a second height H2 within the brush chamber 18. In one embodiment, the optimal position for wet mode cleaning is one in which the microfiber 68 is compressed by the surface to be cleaned S. The second height H2 can therefore be one in which the microfiber 68 is compressed by the surface to be cleaned S.

The brushroll height H1, H2 can, for example, be the distance from the top of the brush chamber 18 to the brushroll axis X. The greater this distance, the lower the brushroll is positioned in the brush chamber 18. In an embodiment where the top of the brush chamber 18 comprises the curved top wall 38 as shown, the brushroll height H1, H2 can be a maximum straight line distance from the brushroll axis X to the top wall 38.

For brushrolls having the same, or substantially the same, diameter, positioning a brushroll lower in the brush chamber 18 will increase the distance the brushroll projects from the bottom of the brush chamber 18 and will increase the amount of floor contact, for example by pressing the agitation element into or against the surface to be cleaned S. As can be appreciated, the diameter of the brushroll also effects the amount of projection or floor engagement.

In an embodiment where the brushrolls 16, 60 have the same, or substantially the same, diameter D1, D2, the second height H2 is greater than the first height, thereby resulting in the first brushroll 16 being positioned higher in the chamber 18 and the second brushroll 60 being positioned lower in the chamber 18. In one non-limiting example, the second height H2 can be about 3.0 mm greater than the first height H1, resulting in the second brushroll 60 projecting about 3.0 mm farther from the bottom of the chamber 18. This height difference is denoted “H3” in FIG. 3 . Other height differences are possible, and may depend on the relative diameters D1, D2 of the brushrolls 16, 60. It is noted that in FIG. 3 , the brushroll 60 is not shown as compressed by the surface to be cleaned S, but rather is shown as uncompressed to illustrate the height difference H3.

To switch from dry cleaning to wet cleaning, the dry tank 14 is removed, which exposes the brushroll 16 in the brush chamber 18. The brushroll 16 is then removed from the brush chamber 18. The wet cleaning brushroll 60 is installed in the brush chamber 18 and the wet tank 40 is installed in the tank receiver 42 that automatically sets the brushroll 60 to an optimal position for wet mode cleaning.

Increased floor engagement with the microfiber brushroll 60 in wet mode cleaning can improve mopping and cleaning of stuck-on stains. Less floor engagement with the bristle brushroll 16 in dry mode cleaning can provide appropriate engagement on soft surfaces such as carpet, and better sweeping on hard floors.

The brushroll height setting features 70, 80 can physically engage with the brushroll 16, 60 to set the height of the brushroll 16, 60 within the brush chamber 18. In one embodiment, the brushroll height can be set automatically the action of installing the tank 14, 40 on the housing 12. In another embodiment, the brushroll height can be set under automated control (e.g. via computer input in a controlled fashion), and the brushroll position setting mechanism of the robot 10 can, for example, comprise a motor or solenoid disposed on the housing 12 or tank 14, 40. In either embodiment, automatic brushroll height adjustment may be preferred over manual height adjustment (e.g. via manual user input or under direct user control) in order to provide consistent and accurate brush positioning based on the cleaning mode, and to remove the margin for user error in setting an optimal brush position.

FIG. 4 shows one embodiment of the dry tank brushroll height setting feature 70 at a passive end, e.g. a non-driven end, of the brushroll 16. The brushroll height setting feature 70 physically engages the brushroll 16 to set its position within the brush chamber 18. It is noted that a substantially similar, or identical, height setting feature 70 can be provided at the opposing, driven end of the brushroll 16, e.g. the opposing end of the brushroll 16 which couples with the drive assembly 30 (FIG. 1 ), and is not described separately for brevity of the disclosure. In yet another configuration, the dry tank brushroll height setting feature 70 can engage the brushroll 16 at one point, for example near the middle of the brushroll 16.

The brushroll height setting feature 70 can comprise an upper brushroll mount 72 fixed on the tank 14 that is adapted to engage an end portion 90 of the brushroll 16 to set the brushroll 16 to a predetermined height. The robot 10 can include a moveable lower brushroll mount 74 adapted to support the end portion 90 of the brushroll 16. The fixed upper brushroll mount 72 is configured to move the brushroll 16 to the predetermined height by engagement with the end portion 90. Engagement of the fixed upper brushroll mount 72 with the end portion 90 moves both the end portion 90 and the lower brushroll mount 74 to positions associated with the predetermined height. Therefore, mounting of the tank 14 on the robot 10 automatically sets the height of the brushroll 16 to the predetermined height. The brushroll height setting feature 70 of the tank 14 and the brushroll mount 74 of the robot 10 can define a brushroll position setting mechanism, also referred to herein as a brushroll height setting mechanism.

The brushroll mounts 72, 74 may engage with various components on the end portion 90 of the brushroll 16. For example, the brushroll mounts 72, 74 can engage a non-rotatable portion of the brushroll 16, such as, but not limited to, an end cap at the end portion 90 of the brushroll 16.

The fixed upper brushroll mount 72 of the tank 14 can have a fixed or predetermined length L1 that automatically sets the brushroll 16 to the first height H1. For example, the upper brushroll mount 72 can comprise an extension 71 on a portion of the tank 14 forming the top wall 38 of the brush chamber 18, such that the extension 71 extends downwardly into the brush chamber 18 and exerts force on the end portion 90 of the brushroll 16.

The moveable lower brushroll mount 74 can comprise a telescopic support 75 that is slideable relative to a fixed lower support 76 for vertical movement of the brushroll 16 within the chamber 18. The telescopic support 75 can be biased away from the fixed support 76 by a spring 78. The spring 78 may, for example, be attached between the telescopic support 75 and the fixed support 76. The fixed lower support 76 is fixed with respect to the brush chamber 18 and can be formed by a fixed portion of the housing 12, such as a portion of a sole plate or a portion of the brush chamber 18.

The lower brushroll mount 74 can be provided within the brush chamber 18, or elsewhere on the housing 12 to support the brushroll 16. In one embodiment, the brush chamber 18 can comprise the lower brushroll mount 74. To install the brushroll 16, the tank 14 is removed from the housing 12, and the brushroll 16 is inserted into the brush chamber 18, for example through the top opening of the brush chamber 18 and mounted to the lower brushroll mount 74. Next, the tank 14 is installed on the housing 12, by which action the upper brushroll mount 72 engages the brushroll 16 and sets the brushroll 16 to a predetermined height and also by which action the tank 14 closes the top opening of the brush chamber 18 with the wall 38. Thus, the single action of mounting the tank 14 secures and sets the height of the brushroll, and closes the brushroll insertion opening of the brush chamber 18.

It is noted that, in some embodiments, the position of the brush motor 32 (FIG. 1 ) may be moveable within the housing 12 to match the brushroll height set by the tank 14, 40. Accordingly, components of the drive assembly 30, such as the belt 34, may also be free to move based on the brushroll height set by the tank 14, 40. In other embodiments, the position of the brush motor 32 may be fixed.

FIG. 5 shows one embodiment of the wet tank brushroll height setting feature 80 at a passive end, e.g. a non-driven end, of the brushroll 60. The configuration of the wet tank brushroll height setting feature 80 may, in one embodiment, be substantially similar to that of the dry tank, including having an upper brushroll mount 82 that is adapted to engage an end portion 92 of the brushroll 60 to set the brushroll 60 to a predetermined height.

The fixed upper brushroll mount 82 of the tank 40 can have a fixed or predetermined length L2 that automatically sets the brushroll 60 to the second height H2. For example, the upper brushroll mount 82 can comprise an extension 81 on a portion of the tank 40 forming the top wall 38 of the brush chamber 18, such that the extension 81 extends downwardly into the brush chamber 18 and exerts force on the end portion 92 of the brushroll 60.

In one embodiment, the length L2 is longer than the length L1 of the dry tank brushroll height setting feature 70 (FIG. 4 ). Accordingly, the telescopic support 75 can be forced further downward and the spring 78 can be compressed to greater extent that with the dry tank brushroll height setting feature 70.

In another embodiment of the invention, the brushroll height setting mechanism 70, 80 is configured to be operated based on reaction forces from the rotation of the brushroll 16, 60. The movement of the brushroll 16, 60 vertically can be based on reaction forces from the brushroll 16, 60 spinning in either the forward direction or the backward direction.

In yet another embodiment of the invention, the brushroll height setting mechanism 70, 80 may be fully integrated with the tank 14, rather than having some components, such as the lower brushroll mount 74, telescopic support 75, fixed lower support 76, and/or spring 78, provided on the housing 12 or brush chamber 18 of the robot 10. As such, the brushroll height setting mechanism 70, 80 may be removable from the housing 12 by the removal of the tank 14, 40. Accordingly, the height-setting of the brushroll 16, 60 is fully provided by the tank 14, 40. In such an embodiment, the drive assembly 30 for the brushroll 16, 60 can be provided on the housing 12 as previously described, or may be at least partially integrated with the tank 14, 40 as well. Where the drive assembly 30 is integrated with the tank 14, 40, drive assembly 30 components such as the belt 34 and/or the motor 32 may be removable from the housing 12 by the removal of the tank 14, 40.

In still another embodiment of the invention, the brushroll height setting feature 70, 80 is configured to be operated under automated control (e.g. via computer input in a controlled fashion), and may be disposed on the housing 12, the tank 14, 40, or a combination of the housing 12 and the tank 14, 40. The controller 22 is configured to detect whether the tank 14, 40 mounted to the housing 12 is a dry tank or a wet tank, and provides input to control the brushroll height setting mechanism accordingly. For example, with detection of the dry tank 14, the controller 22 can provide input to move a brushroll to the first position or first height H1. With detection of the wet tank 40, the controller 22 can provide input to move a brushroll to the second position or second height H1.

In such an embodiment, where the brushroll height setting is operated under automated control, the tanks 14, 40 do not necessarily require brush height setting features. Therefore, components of the brushroll height setting mechanism may be disposed on the housing 12, on the tanks 14, 40, or a combination of the housing 12 and the tanks 14, 40.

FIGS. 6-7 are schematic views of a robot 10A, according to another aspect of the present disclosure, in which like elements are referred to with the same reference numerals used for the previous embodiment bearing the letter “A”. The robot 10A has a dual brushroll configuration, with two brushrolls 16A, 60A mounted in a brush chamber 18A, including a first or bristle brushroll 16A (FIG. 6 ) and a second or microfiber brushroll 60A (FIG. 7 ). In one configuration, the robot 110 is adapted for both dry and wet cleaning, and includes interchangeable tanks, including a first or dry tank 14A (FIG. 6 ) and a second or wet tank 40A (FIG. 7 ).

The dry tank 14A has brushroll height setting features 100, 102 configured to engage the brushrolls 16A, 60A, respectively, to set the position or height of each brushroll 16A, 60A within the brush chamber 18A to an optimal position for dry mode cleaning. In one embodiment, the optimal position for dry mode cleaning is a position or height where the agitation elements of the brushrolls 16A, 60A just touch the surface to be cleaned S.

The wet tank 40A has brushroll height setting features 104, 106 configured to engage the brushrolls 16A, 60A, respectively, to set the position or height of each brushroll 16A, 60A within the brush chamber 18A to an optimal position for wet mode cleaning. In one embodiment, the optimal position for wet mode cleaning is a position or height where the agitation element of at least one of the brushrolls 16A, 60A is compressed by the surface to be cleaned S.

For example, the brushroll height setting feature 106 can be configured to set at least the microfiber brushroll 60A to a second position or height within the brush chamber 18 where the microfiber is compressed by the surface to be cleaned S, e.g. to lower the microfiber brushroll 60A. The wet tank 40A may or may not be configured to move the bristle brushroll 16A to a different position.

By interchanging the tanks 14A, 40A, the brushrolls 16A, 60A can be automatically positioned for the cleaning mode associated with the tank 14A, 40A. Therefore, the brushrolls 16A, 60A do not have to be changed out when switching between cleaning modes.

The dual-brushroll robot 10A can have at least one lower brushroll mount 74A or other features that cooperates with one or more of the brushroll height setting features 100, 102, 104, 106 to define a brushroll height setting mechanism. In other embodiments, one or more of the brushroll height setting features 100, 102, 104, 106 may be operated under automated control (e.g. via computer input in a controlled fashion).

In any of the embodiments disclosed herein where the robot 10 includes multiple, interchangeable tanks and/or multiple, interchangeable brushrolls, the docking station (not shown) for the robot 10 can store the spare tank and/or brushroll not installed on the robot 10.

It is noted that, while robots with multiple interchangeable tanks and/or brushrolls are discussed herein, aspects of the disclosure are applicable to a robot having one tank and one brushroll, one tank and multiple brushrolls, or multiple tanks and one brushroll. For example, a hybrid brushroll having both bristles and microfiber may be suitable for both dry and wet cleaning, and may be set to an optimal position for dry or wet cleaning depending on a desired cleaning mode.

Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientations.

The terms “comprising” or “comprise” are used herein in their broadest sense to mean and encompass the notions of “including,” “include,” “consist(ing) essentially of,” and “consist(ing) of.” The use of “for example,” “e.g.,” “such as,” and “including” to list illustrative examples does not limit to only the listed examples. Thus, “for example” or “such as” means “for example, but not limited to” or “such as, but not limited to” and encompasses other similar or equivalent examples. Any reference to elements in the singular, for example, using the articles “a,” “an,” “the,” or “said,” is not to be construed as limiting the element to the singular.

To the extent not already described, the different features and structures of the various embodiments of the invention, may be used in combination with each other as desired, or may be used separately. That one surface cleaning apparatus is illustrated herein as having all of these features does not mean that all of these features must be used in combination, but rather done so here for brevity of description. Thus, the various features of the different embodiments may be mixed and matched in various vacuum cleaner configurations as desired to form new embodiments, whether or not the new embodiments are expressly described.

The above description relates to general and specific embodiments of the disclosure. However, various alterations and changes can be made without departing from the spirit and broader aspects of the disclosure as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. As such, this disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the disclosure or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments.

Likewise, it is also to be understood that the appended claims are not limited to express and particular compounds, compositions, or methods described in the detailed description, which may vary between particular embodiments that fall within the scope of the appended claims. With respect to any Markush groups relied upon herein for describing particular features or aspects of various embodiments, different, special, and/or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims. 

1. An autonomous floor cleaner, comprising: an autonomously moveable housing comprising a brush chamber; an autonomous drive system; a tank adapted to hold at least one of liquid and debris; a brushroll mounted within the brush chamber; a brushroll drive system comprising a brushroll motor operably coupled with the brushroll; and a brushroll height setting feature coupled with the tank and configured to engage the brushroll to set the height of the brushroll within the brush chamber.
 2. The autonomous floor cleaner of claim 1, wherein the tank is removably mounted on the housing, and wherein installation of the tank on the housing physically engages the brushroll height setting feature with the brushroll to set the height of the brushroll within the brush chamber.
 3. The autonomous floor cleaner of claim 1, comprising a moveable lower brushroll mount adapted to support the brushroll.
 4. The autonomous floor cleaner of claim 3, wherein the moveable lower brushroll mount comprises a spring-biased, telescoping support disposed on the housing.
 5. The autonomous floor cleaner of claim 3, wherein the brushroll height setting feature comprises an upper brushroll mount extending downward from a bottom wall of the tank into the brush chamber to physically engage the brushroll, overcoming a spring bias of the lower brushroll mount to vertically position the brushroll at a predetermined height relative to a surface to be cleaned.
 6. The autonomous floor cleaner of claim 1, comprising at least one cleaning system chosen from: a vacuum collection system comprising a suction nozzle inlet and a suction source comprising a vacuum motor, wherein the tank is in fluid communication with the suction nozzle inlet; a fluid delivery system comprising a fluid supply tank and a fluid distributor positioned to dispense cleaning fluid onto the brushroll; and a fluid recovery system comprising a suction nozzle inlet and a suction source comprising a vacuum motor, wherein the tank is in fluid communication with the suction nozzle inlet.
 7. The autonomous floor cleaner of claim 1, wherein a wall of the tank defines a top wall of the brush chamber.
 8. The autonomous floor cleaner of claim 7, comprising an inlet opening in the housing, wherein the brushroll is rotatably mounted in the inlet opening to contact a surface to be cleaned below the housing.
 9. The autonomous floor cleaner of claim 1, wherein: the brushroll is a first brushroll; the autonomous floor cleaner is configured to receive a second brushroll; and the first brushroll and the second brushroll are adapted to be interchangeably mounted within the brush chamber.
 10. The autonomous floor cleaner of claim 9, wherein: the tank is a first tank; the autonomous floor cleaner is configured to receive a second tank; and the first tank and the second tank are adapted to be interchangeably mounted within a tank receiver disposed on the autonomously moveable housing.
 11. The autonomous floor cleaner of claim 1, wherein: the brushroll is a bristle brushroll; the autonomous floor cleaner is configured to receive a microfiber brushroll; and the bristle brushroll and the microfiber brushroll are adapted to be interchangeably mounted within the brush chamber.
 12. The autonomous floor cleaner of claim 11, wherein: the tank is a dry tank adapted to hold dry debris and the brushroll height setting feature comprises a first brushroll height setting feature configured to engage the bristle brushroll to set the height of the bristle brushroll to a first predetermined height within the brush chamber; the autonomous floor cleaner comprises a wet tank adapted to hold liquid and debris, the wet tank comprising a second brushroll height setting feature configured to engage the microfiber brushroll to set the height of the microfiber brushroll to a second predetermined height within the brush chamber; and the dry tank and the wet tank are adapted to be interchangeably mounted within a tank receiver disposed on the autonomously moveable housing.
 13. The autonomous floor cleaner of claim 1, wherein: the brushroll is a first brushroll; the autonomous floor cleaner comprises a second brushroll mounted within the brush chamber contemporaneously with the first brushroll; and the brushroll height setting feature is configured to engage the first brushroll and to not engage the second brushroll.
 14. An autonomous floor cleaner, comprising: an autonomously moveable housing comprising a brush chamber; an autonomous drive system; a tank adapted to hold at least one of liquid and debris; dual-rotating brushrolls mounted within the brush chamber, the dual-rotating brushrolls comprising a first brushroll and a second brushroll; a brushroll drive system comprising a brushroll motor operably coupled with the dual-rotating brushrolls; and a brushroll height setting mechanism configured to set the first brushroll at a first height setting in a first cleaning mode and to set the first brushroll at a second, different height setting in a second cleaning mode.
 15. The autonomous floor cleaner of claim 14, wherein the first cleaning mode is a dry cleaning mode and the second cleaning mode is a wet cleaning mode.
 16. The autonomous floor cleaner of claim 14, wherein the first cleaning mode is a carpet cleaning mode and the second cleaning mode is a hard floor cleaning mode.
 17. The autonomous floor cleaner of claim 14, wherein the brushroll height setting mechanism comprises at least one brushroll height setting feature coupled with the tank.
 18. The autonomous floor cleaner of claim 17, comprising a spring-biased lower brushroll mount adapted to support the first brushroll, wherein the brushroll height setting feature comprises an upper brushroll mount extending downward from a bottom wall of the tank into the brush chamber to physically engage the first brushroll, overcoming a spring bias of the lower brushroll mount to vertically position the first brushroll at a predetermined height relative to a surface to be cleaned.
 19. An autonomous floor cleaner, comprising: an autonomously moveable housing comprising a brush chamber having a top opening and a lower brushroll mount; an autonomous drive system; a brushroll removably mounted within the brush chamber and supported by the lower brushroll mount; a brushroll drive system comprising a brushroll motor operably coupled with the brushroll; and a tank adapted to hold at least one of liquid and debris, the tank having a wall closing the top opening of the brush chamber and an upper brushroll mount projecting downwardly from the wall; wherein the tank is removably mounted on the housing, and wherein installation of the tank on the housing physically engages the upper brushroll mount with the brushroll to adjust the vertical position of the brushroll within the brush chamber.
 20. The autonomous floor cleaner of claim 19, wherein the brushroll comprises a non-rotatable portion and the lower brushroll mount comprises a spring-biased, telescoping support disposed within the brush chamber that engages the non-rotatable portion. 